Composition and process of making the same



March 17, 1953 B. J. CRAIG 2,631,355

I COMPOSITION AND PROCESS OF MAKING THE SAME Filed June 9, 1944 5Sheets-Sheet 1 March 17, 1953 B. J. CRAIG COMPOSITION AND PROCESS OFMAKING THE SAME 3 Sheets-Sheet 2 Filed June 9, 1944 INVENTOR.

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March 17, 1953 B. J. CRAIG 2,631,355

COMPOSITION AND PROCESS OF MAKING THE SAME Filed June 9, 1944 3Sheets-Sheet 3 Patents 17, 1953 COMPOSKTIUN AND PROCESS OF MAKING THESAME Burnie J. Craig, San Gabriel, (Calif.

Application June 9, 19%, Serial No. 539,533

1e Claims. (Cl. Bil- 80) In the manufacture of composition cork thecomminuted cork is mixed with a binder and the mixture is fed to asuitable forming machine or die. Care must be taken to insure a thoroughmixing and there should be no swelling or distorting of the corkparticles or any premature insolubilizing of the binder.

Also, in manufacturing cork compositions, when the binder and corkparticles are mixed, there is a tendency for the binder to enter thepores of the cork and remain in the pores and there is also a tendencyfor the binder to enter the pores during the molding or other treatingoi the composition in the steps of making the finished product.

It is one of the objects of this invention to provide a composite corkpreparation which overcomes the difficulties mentioned and which hasdesirable physical properties.

Another object of the invention is to provide a novel method of making acomposition which includes porous members.

A further object of the invention is to provide a novel porouscomposition.

An additional object of the invention is to provide a novel apparatusfor making a porous composition.

A further object of the invention is to provide a novel method of makinga cork composi tion wherein cork phere of gas above atmosphericpressure, are mixed with a binder, after which the binder isinsolubilized.

further object or the invention is to provide .a novel method whereinporous particles, while containing gas, are individually or in groupscovered with a. film. which entraps the contained gas.

An additional object of the invention is to provide an improved corkcomposition including cork particles wherein the particles containentrapped gas which may have a pressure greater than atmosphericpressure.

A further object of the invention is to provide a novel method of makinga cork composition wherein cork particles, while containing a gas underpressure, are mixed with a binder and thereafter the pressure exteriorto the composi tion is reduced to permit the entrapped gas to expand sothat it tends to force binder from the pores of the cork particles.

A further object or" the invention is to provide a novel method ofmaking a cork composition wherein cork particles, while containing a gas,under, pressure, are mixed with a binder and particles, while in anatmosthereafter the pressure exterior to the composition is reduced toless'than that of the entrapped gas, thus permitting the entrapped gasto expand and to force binder from the pores of the cork particles,after which the binder is insolubilized.

Another object of the invention is to provide a novel method of making acork composition wherein cork particles, while containing gas underpressure aboveatmospheric, are individually or in groups covered with afilm which entraps the contained gas, after which the gas entrappingparticles are secured together to-form a composition or a thread-likemember.

Another object of the invention is to provide a novel method of making acork composition wherein cork particles, while containing gas underpressure above atmospheric, are individually or in groups covered with afilm which entraps the contained gas, after which the gas entrappingparticles are mixed with a binder under pressure conditions which maypermit the entrapped. gas to expand.

A further object of the invention is to provide a novel cellular system.

Another object of the invention is to provide a novel method making acellular system.

A further object or" the invention is to provide a novel apparatus formaking a cellular system.

A further object of the invention is to provide a novel cellularcomposition member having a core therein.

A further object of the invention is to provide a composition includinga core having gas containing, porous members thereabout.

A further object of the invention is to provide a novel method of makinga composition which includes a core with deformable members thereabout.

A further object of the invention is to provide a novel apparatus formaking a cork composition.

Other objects and advantages of the invention will be apparent from thefollowing description taken in connection with the accompanying drawins, wherein:

Fig. i is a central sectional view through an apparatus embodying thefeatures of the invention;

Fig. 2 is a sectional view showing one of the particles;

Fig. 3 is a section taken on line 3-3, Fig. 1, showing the material;

Fig. 4 is a section taken on line t-t, Fig. 1,

' showing the material;

Fig. 5 is a view similar to Fig. 3, showing material when the individualcovering for the particles is omitted;

Fig. 6 is a view similar to Fig. 4, showing material when the individualcovering for the particles is omitted;

Fig. '7 is a view similar to Fig. 1, showing a modified apparatus;

Fig. 8 is a longitudinal, central, sectional view showing the cellularsystem with the binder omitted;

Fig. 9 is a view similar to Fig. 8, showing material with the binder andthe particle covering omitted;

Fig. 10 is a section showing material with the particle covering, outercovering and binder;

Fig. 11 is a sectional view showing material with the particle coveringomitted;

Fig. 12 is a view similar to Fig. 10 with the outer covering omitted;

Fig. 13 is a view similar to Fig. 11 with the outer covering omitted;

Fig. 14 is a section taken on line I i-I4, Fig. 8;

Fig. 15 is a view similar to Fig. 1, showing a further modification;

Fig. 16 is a longitudinal, central, sectional view, showing the tensilemember and associated parts;

Fig. 17 is a section taken on line i'l-ll', Fig. 16;

Fig. 18 is a view similar to Fig. 17 with the binder omitted;

Fig. 19 is a view similar to Fig. 17 with the outer cover omitted;

Fig. 20 is a view similar to Fig. 17 with both 5 cover and binderomitted;

Fig. 21 is a plan View of a fabric embodying features of the invention;

Fig. 22 is a section on line 22-22, Fig. 21, and

Fig. 23 is a top plan view of a packing member.

Referring to the drawing by reference characters, an apparatus embodyingthe features of the invention is indicated generally at A. Thisapparatus includes a housing I0, having a funnel shaped container II inthe top thereof. The container has a cylindrical hopper portion l2 atthe bottom thereof inwhich a rotating hopper gate 13 is mounted. Theinterior of the housing communicates with a gas pressure conduit 14 andwith a constant pressure outlet valve l5 which determines the minimumair pressure within the housing [0. Also communicating with the interiorof the housing I0 I show an outlet 18 with a constant pressure inletvalve 11 therein which determines the maximum pressure within thehousing.

Extending into the housing I show a plurality of injection jets H3. Thebottom of the housing is tapered inwardly as at l9 and has a cylindricalhopper portion 20 at the bottom thereof in which a rotating hopper gate2| is mounted.

In operation, porous particles 22 are placed in the container ll whilegas under pressure is maintained within the housing I0 by means of theconduit M and is maintained at a desired pressure by means of the valvesl5 and I1. As the rotating hopper gate I3 is rotated, the smallparticles of porous material are allowed to fall into the housing andthrough the path of the sprays where they become coated with coveringmaterial. As the particles fall they may be vulcanized or cured so thatwhen the particles reach the bottom portion of the housing they may beremoved by means of the rotating hopper gate 2|. Thus it may be seenthat compressed gas is entrapped in the pores of the porous particlesand sealed therein by the coating of material 23 about each particle asshown in Fig. 2.

The members 24, formed as described, are compressible as well asresilient and elastic due to the contained gas and due to their naturalproperties.

The porous particles pass from the gate 2| to a discharge spout 25,whence they pass through a distributor 26 which is preferably regulatedto run at a proper speed so that the particles are fed evenly. From thedistributor 26 the particles pass through a discharge portion 2'! into acylindrical member 28 which contains a conveyor, shown as a rotatingscrew 29, which is suitably driven to rotate and to advance theparticles 24 along the member 28.

A hopper 30, having a discharge feed valve 3| therein, communicates withthe member 28. The hopper 30 receives a binder element 32 which isdischarged on the particles within the member 28. The member 28 includesa discharge portion 33 which includes an impeller 34 driven by asuitable means 35. The-impeller 3 agitates and forces along the mixtureof binder and particles 24 and discharges the material into a conveyor36 which runs over drums 31 whose upper reach is supported by a table33. Rollers 39 and 40 serve to smooth the composition which is indicatedat 4!. The composition may advance through a coating chamber 22 whichcontains a coating or covering material 33. The chamber 42 has opposedslots of slightly greater area than the cross section area of thecomposition 4|, so that the coating 44 is applied about the compositionas the latter passes through the chamber 42.

The gas in the container I0 has a pressure preferably above that of theatmosphere and, since the parts are enclosed, the gas entrapped in theparticles 24 has a pressure above atmospheric. The binder is fed intothe chamber 28 under a pressure which is preferably equal to thepressure of the entrapped gas, so that upon the mixing of the binder andparticles there is no tendency for a change in volume of the particles.The conveyor 36 and associated parts are arranged in a container 45 inwhich an evaporative atmosphere and a coagulating bath may be maintainedat a desired pressure by pipes 46 and 48'.

The pressure in the container 45 is preferably less than the pressure ofthe gas entrapped in the particles. so that when the plastic compositionbecomes subject to the pressure in the container 45 the drop in pressurewill cause the particles to expand as the gas contained therein expands.

The manner in which the particles are united and/or treated and/orfinished will depend upon the intended use of the finished composition.For example, in the composition shown in Fig. 3 the coated, gasentrapped members 24 are secured together by a binder 32, but there isno outside cover. Omission of a supply of coating material 43 providesthis type. In Fig. 4 the composition is the same as that shown in Fig. 3except that an outside coating 44 is provided. In Fig. 5 the coating 23and coating 44 are omitted to provide a composition which includes airentrapped particles 22, held by a binder 32. In Fig. 6 the compositionis the same as that shown material.

- filament 72 passes and is larger diameter than, the lower end 55 ofthe tube 50, which is disposed in the outlet 54 so that an annularpassage 56 is provided through which the material is extruded. Bindermaterial 51 is supplied by a pipe 58 which is shown as communicatingwith the tube 59 above the container As the'particles 6!) advance theyare first covered with a coating 6! similar to the coating 23 previouslydescribed. The coated gas entrapping particles pass into the tube 58where they may be mixed with binder 51. The particles and binder arethen discharged from the tube i! into the tube 62 which is formed by theextruded material 52. The tube 62, with particles therein and with thebinder, passes through a tube Ed in a housing 65 into a chamber 66 inthe housing where a coagulating bath or evaporative atmosphere may besupplied by pipes 67 to finish the From the chamber 68 the materialpasses to the housing 65 from which it may be carried and packaged forshipment.

When an evaporative atmosphere is emplo ed in the chamber 66 this may besupplied by pipes '61 or pipes 51' since the housing 65 and chamber 65communicate through an opening 61". When a bath is provided in thechamber 55 the bath material may be supplied by pipes 6'! and a gasunder pressure by the pipes 61'. The pressure in the housing 65 andchamber 66 may be greater than, the same as, or less than, the pressureof the gas entrapped within the particles. If the pressure is greater itwill tend to cause the tube 62 to more tightly engage the particlesprior to the curing of the tube so that the particles will be clamped bythe tube. If the pressure is less than that of the entrapped air in theparticles, the particles and tube will tend to expand prior to finishingthe tube so that a more buoyant cellular system will be provided.

The material shown in Fig. will be produced by operating the machinewith all or" the material supplied thereto. When the binder is omitted,material such as shown in Fig. 8 is produced and when both binderandparticle covering are omitted, material shown in Fig. 9

results. When the particle covering only is omitted the material shownin Fig. 11 results, while, when the outer covering is omitted, thematerial shown in Fig. 12 results. When the particle covering and outercovering are omitted, material of the character shown in Fig. 13 will beproduced.

In Fig. an apparatus is disclosed which is adapted for making cellularsystems 59, containing a tensile member. This apparatus includes acontainer EU in which a pair of guide rolls'll are mounted. A core,tensile member or filament is supplied from a. roll 13 and passes overthe rolls H through the container in which is adapted to containadhesive material 14 through which the coated therewith. From thecontainer 10 the adhesive coated filament passes through an inlet. tube15in the bottom Y suitable manner.

of a container 16 which contains porous granules IT. The granules adhereto the adhesive on the filament 12 as shown in Fig. 15. The container 7Bis provided with a supply of warm air or other drying agent from anozzle 18 so that the adhesive is dried or cured as it passes throughthe upper portion of the container 16.

The filament and attached porous particles pass through an outlet 19between rolls l9 and over rolls and 8| which may be driven to suitablyadvance the filament. From the roll 8| the filament passes downwardlyinto a tube 50' and to an apparatus similar to that shown at 5|, 52',53, etc., Fig. '7. In Fig. 15 parts corresponding to those previouslydescribed in connection with Fig. 7 are designated by similarly primedreference numerals.

As the filament with the porous particlesthereon passes through the tube593'. it is covered with a binder 5i" and as it passes downwardlycoating material 52' is extruded to form a tube or coating 62 which isdisposed about the granules II. The entire apparatus shown in Fig. 15 isenclosed in a housing 82 and gas under pressure is supplied to thehousing from pipes 83. The air under pressure enters the container 16through openings 84, causing the pores in the particles therein to befilled with compressed gas. The container 65' which may contain acoagulating bath or evaporative atmosphere is similar to the container66 previously described.

In Fig. 17 the cellular member is shown as including a filament 12having adhesive 14 thereupon and having particles 1'. connected theretoby the adhesive. The system also includes a binder 51 and outer cover62.

In Fig. 18 the construction is the same as shown in Fig. 17 except thatbinder 51' is omitted.

In Fig. 19 the construction difiers from that shown in Fig. 17 in thatthe cover is omitted while in the construction shown in Fig. 20 both thecovering and binder are omitted.

In Figs. 21 and 22 a fabric 98 is disclosed. This is made by weaving thecellular members 69 in a Other cellular members of the characterdisclosed in the preceding description may be employed in makingthefabric. It will be understood that the fabric will be buoyant, flexibleand pliant and that due to the contained porous members it will havesufficient body to permit its use for many purposes.

In Fig. 23 a packing member 91 is disclosed.

This member may be made by arranging one of the strands described abovein the desired shape and then securing it in this shape by means of .thebinder.

: tate, cellulose pro ionate, cellulose acetate-propionate, methyl,ethyl, ethyl or benzyl cellulose,

- colloidal dispersions of proteins such as casein, gelat n and thelike. Other material such as artificial resins of various kinds may beused.

The covering material might also be natural I rubber or a synthetic orthe butadiene co-polymer type such as Buna-S rubber, a synthetic of .thechloroprene polymer type, such as neoprene, a synthetic of theisobutylene polymer type having small quantities of other diolifinessuch as isoprene or butadiene, such as Butyl rubber or a plasticizedvinyl chloride polymer, such as Koroseal. The natural or artificialrubber may be employed in latex form with the latices applied to theparticles in sufficient quantities to provide the necessary thickness.

The binder and/or the material which secures the particles to the coremay be a thermo setting type such as urea, phenolic or alkyd resinousmaterials or albumens or proteins treated with a material toinsolubilize them upon heating, or other types of binders may beemployed as, for example, raw natural rubber which may be vulcanized forthe binding effect; also latices may be employed as binders andregenerated cellulose formed from viscose may be employed.

The covering material with the contained particles may be extruded intoa coagulating bath or into an evaporating atmosphere so that thematerial will have the desired physical characteristics.

The core or tensile member may consist of a linen, cotton or silk threador a rubber thread, or it may be made of wire such as copper.

Having thus described the invention, I claim:

1. A composition comprising compressible porous flexible, independentparticles, each particle having a gas impervious coating completelysurrounding it, each particle containing gas at a pressure aboveatmospheric pressure, and flexible means holding the particles together.

2. A composition comprising compressible porous, flexible particles,each particle having an independent covering, and a binder holding thecovered particles in a unitary mass.

3. A flexible cellular system comprising a plurality of flexible porousparticles, a flexible gas impervious covering surrounding each particle,

and a flexible, tubular elongated member arranged about the coveredparticles to form a strand.

4. A flexible cellular system comprising a plurality of porousparticles, gas in the pores of said particles, a gas impervious coveringsurrounding each particle, means binding the particles and coveringstogether, and a flexible tubular covering about the binder.

5. A method of making a porous composition comprising taking porousflexible particles, separating the particles, spraying a flexible, airimpervious, independent covering on each of the particles while they areseparated to provide a plurality of independently covered porousmembers, and thereafter uniting the independent members by a binderwhich unites the members.

6. The method of making a cellular system comprising taking independentcomminuted flexible particles and arranging the particles in axialalignment and uniting the particles and thereafter placing a continuousflexible covering over the united particles to form a flexible strand.

7. The method of making a cellular system comprising taking comminutedorous particles, running an adhesive bearing, flexible, tensile memberthrough the particles to cause the particles to adhere to the tensilemember, forcing the porous particles against the tensile member,arranging a binder about the particles and tensile member to form aunitary mass, and thereafter placing a covering about the binder andparticles.

8. As an article of manufacture, a granule of flexible, compressiblematerial having outwardly opening surface pores, said granules having aflexible, impervious coating completely surrounding and covering thegranule and closing the surface pores thereof and a filling of gas inthe pores of the granule, the gas being at a pressure above atmosphericand tending to force the coating from the pores, the gas pressure beingbelow the pressure at which the coating would be ruptured.

9. A flexible cellular system having a flexible filamentous core andporous, compressible, flexible, resilient particles inflated to apressure above atmospheric and entirely surrounding the core and securedto the core to form a strand.

10. A flexible cellular system comprising a plurality of flexible,compressible, independent particles, said particles having outwardlyopening pores therein, said pores containing gas under pressure, sealingmeans about the particles and sealing the pores to entrap the containedgas therein, and a flexible covering about the sealing means andtheparticles sealed thereby.

11. A cellular system comprising a continuous, elongated, flexible,resilient, tubular member having a plurality of spaced, flexible,resilient members secured therein.

12. A fabric including woven strands, each strand comprising acontinuous, elongated member including a plurality of particles havingoutwardly opening pores therein, said particles being arranged in afilamentous manner to form a thread, and means sealing the pores anduniting the particles.

13. A flexible cellular system including a flexible core having a singlelayer of porous, compressible particles surrounding and secured to thecore, a binder about the particles, and a flexible, continuous, tubularmember surrounding and engaging the binder and particles.

14. A fabric including woven strands, each strand comprising acontinuous, elongated member including a plurality of particles havingoutwardly opening pores therein, said particles being arranged about afilament per se and means sealing the pores and uniting the particles toform a coated thread.

BURNIE J. CRAIG.

file of this patent:

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